Molding form for structural material



Dec. 7 1937. D. M. BOWES MOLDING FORM FOR STRUCTURAL MATERIAL Filed May4, 1934 3 Sheets-Sheet l Dec. 7, 1937. D. M. BOWES MOLDING FORM FORSTRUCTURAL MATERIAL 5 Sheets-Sheet 2 Filed May 4, 1934 Dec. 7, 1937. DiM, BOWES 2,101,019

I MOLDING FORM FOR STRUCTURAL MATERIAL Filed May 4, 1954 3 Sheets-Sheets V -gm i a 5a I llllm Patented Dec. 7, 1937 UNITED STATES PATENT OFFICEMOLDING FORM FOR STRUCTURAL 21 Claims.

ployed have been open to certain serious disadvantages. In the firstplace, such forms have been relatively expensive initially, and uponcompletion of the particular job in which they were used, they wereeither discarded or, if salvaged, required relatively expensivereconditioning. These former devices were difficult of construction andof removal from the set concrete. Also, transportation of prefabricatedor factory made forms has been relatively expensive and diflicult due tothe fact that heavy materials are necessary to withstand the roughhandling in use and re-use. Collapsible and portable forms or materialsdesigned to create shapes and voids in poured concrete structures haveheretofore been made of relatively heavy and cumbersome materials tofulfill their function and withstand the rough handling of use andre-use. There have also been numerous objections with respect to certaindetails of these prior forms.

To overcome the above objections, and others not specifically mentioned,is one of the objects of my invention.

Another object of my invention is to provide a 35 form for the moldingof structural materials that may be economically and readilymanufactured and transported.

Yet another object of my invention is to provide such a form that is soinexpensive to manufacture that it may be readily discarded upon settingof the various structural materials or simply left in place.

A still further object of my invention is to provide a novel materialfrom which a form may be manufactured.

With these and other objects in view, which may be incident to myimprovements, the invention consists in the parts and combinations to behereinafter set forth and claimed, with"th understanding that theseveral necessary elements comprising my invention may be varied inconstruction, proportions and arrangement without departing from thespirit and scope of the appended claims.

In order that my invention may be more readily material by setting. Theforms heretofore emunderstood, reference is made to the accompanyingdrawings, in which several specific embodi ments of my invention aredepicted, it being distinctly understood, however, that variousmodifications may be made therein without departing from the spirit ofmy invention. In these drawings, in which similar numerals refer tocorresponding parts:

Figure 1 is a top plan view of one embodiment of my invention, showing aportion of structural material deposited thereon.

Figure 2 is a sectional view along the line 22 of Figure 1, looking inthe direction of the arrows.

Figure 3 is a plan view of the plane material from which the form ismade'up, and showing the scoring or stamping thereon and cut outportions necessary for the embodiment of Figure 1 Figure 4 is adetailedperspective view of the device shown in Figure 1.

Figure 5 is a detailed viewof the walls and ribbed member priorto'folding.

Figure 6 is a detailed view showing that section of the device which isrepresented inFigure 5, after the same has been folded and assembled.

Figure 7 is a sectional view along the line 'i''l of Figure 6, lookingin the direction of the arrows.

Figure 8 is a view of one means for binding two adjoining sectionstogether.

Figure 9 is a sectional View along the line 9-9 of Figure 8, looking inthe direction of the arrows.

Figure 10 is a detail view of an alternative means for binding twosections together.

Figure 11 is a sectional view along the line I I -l l of Figure 10,looking in the direction of the arrows.

Figure 12 is a view in perspective of a supporting means for the form,and also of one arrangement for the reinforcing means.

Figure 13 is a detailed view of the device shown in Figure 12, with themolding form and concrete in position.

Figure 14 is a sectional view of a slight modification of the deviceshown in Figure 1, and in which a pair of reinforcing rods are employed.

Figure 15 is a top plan view of the modified form of my invention shownin Figure 14.

Figure 16 is a plan view of the plane material prior to bending andfolding to secure a structure such as shown in Figures 14 and 15.

Figure 17 is another modification of the mold- Figure 19 is a top planview of the modification shown in Figures 1'7 and 18.

Figure 20 is a view of the plane material prior to bending and foldingin order to secure a form such as shown in Figures 17 through 19.

Figure 21 is a View of a modified form of the device shown in Figure 1,and in which the reinforcing ribs are turned inwardly of the raisedportions.

Figure 22 is a sectional view of the device shown in Figure 21, and withthe strengthening ribs turned inwardly.

While I shall refer herein to my invention as being adapted for thepouring of concrete, it will of course be understood that it may beemployed for various other materials, such as gypsum, for instance.

The substances of which my molding forms may be made are many andvarious, and will be referred to in more detail hereinafter; 'One of theprincipal characteristics of my invention is that I employ to advantagethe strength and stiffness of a light plane material by so bending andshaping such material that there are provided a plurality of relativelysmall units. By thisshaping suflicient strength is imparted to supportlarge areas or masses of a superimposed material during a periodsufficient to develop within such superimposed mass the inherentqualities of strength of that mass.

Inasmuch as a relatively heavy cardboard may be employed, I shall referto the material of my molding form as such.

Referring to Figure 1, such cardboard may be bent so that there isformedv a plurality of raised portions I. I have shown this raisedportion as a plane square surface, but as will be seen hereinafter, suchraised portion may assume various shapes. Side walls 2 extend from theraised surface I to-channels 3. As disclosed in the drawings, these sidewalls may be sloping. It will be noted that the channels 3 intersect oneanother and form, in effect, a mesh-like arrangement.

The size of the raised portions, walls and channels will vary with thetype of material which is superimposed thereon. While not desiring to belimited to any specific figures, I have found that, when the form ismade of corrugated fiber boards, and where the imposed material isreinforced, the reinforcement may be placed ap proximately sixteeninches on center, and the surface I will have an area of aboutsixty-four square inches. The bending of the form into the shapedepicted in Figures 1 and 2 suiiices to support approximately threeinches of concrete for the necessary time to allow such concrete to set.The dimensions mentioned herein may be varied, however, as occasionwarrants.

As best'shown-in Figures 2 and 4, I secure additional strength in my.form by using the strengthening ribs 5. These ribs are, in effect,extensions of the side walls 2 at the point that such side walls join acontiguous .wall. These ribs, therefore, are actually composed of twolayers of the material bent back upon one another. As best shown inFigures 2 and 6, these ribs have a free edge 6 which slopes downwardlyfrom the plane surface I, and also a vertical edge I. The vertical edgeI is adapted to abut against the corresponding edges of adjoining units,as shown in Figure 4. The'point of this abutment is substan ially thecenter ofintersection of the channels 3.

' Referring to Figure 3, there is disclosed a view of the substance fromwhich the form i$ made up, showing the scoring or stamping thereon forguidance in bending or folding of the material. In the drawings, forinstance, the dotted lines 8 indicate the line along which the materialmust be bent in order to secure the plane surface I. The lines 9represent the bends that are necessary to form the junction between twoside walls.

A further fold II is made in the material I, in.

onal cutaway section I2 forms the vertical edge I. If desired, eachfolded half of the rib: 6 may be cut out as at I3 and provided with atab I4. As shown in Figure '7, the tab I4 is adapted to be insertedthrough the notch I3 of the opposed section and bent back. These tabsserve to maintain the several portions of the rib as a unit. The cutawaysections I3 permit the concrete to flow through the ribs into adjacentchannels.

As best shown in Figure 2, reinforcing rods I5 may rest upon theintersecting ribs 5, and be supported above the base of the channels 3.The transverse rods are then arranged in the transverse channels andupon the other rods [5. It will be seen that the reinforcing rods I5permit the flow of concrete therebelow, and thus become embedded wellwithin the concrete.

There is also shown in Figure 2 a falsework I6, upon which the moldingform and concrete may be supported until the concrete sets. Preferablythe channel portions 3 rest upon this fmsework and may be securedthereto by means of nails or other fastening devices I 'I. After theconcrete has set, the falsevvork may be removed, while the nails remainembedded in the concrete. These nails may then be used to secure lathingor other covering means to the base of the concrete.

In Figures 1 through 4, I have shown a molding formrthat is adapted foruse'when only a Single reinforcement is desired in eachchannel. Of

course, the number of reinforcements can be increased, and there isdisclosed in Figures l l through 16 the slight modification that isneces sary to accomplish this. Instead of prOVidlng a V-shaped channelsuch as in Figures 1 through 4, I here provide a flat base 3a for thechannel. Referring to Figure 16, it will be noted that the lines 8, 9and II are provided, along which folds are made, the same .as in Figures1 through 4, However, an additional area is left between com tiguousdesigns, in order to provide for the flat base of the channel 3a.Furthermore, folds 9 and II are extended as at 90. and I la in order toprovide extensions 5a of the strengthening ribs. Also, it is necessaryto slit the material along the line I8 in order to permit the angularadjustment between rib 5 and its extension 5a. As shown by the dottedlines in Figure 14, the rib 5 extends within the rib extension 5a. Also,a square out out section I9 is made in lieu of the hexagonal cut awaysection I2 of Figure 3. It is of course obvious that tabs, such as I4,may be employed upcnboth the ribs 5 and extensions 5a of thismodification.

With this arrangement it will be noted that the reinforcing rods I5 maybe arranged in pairs within each channel, while the transverse rods maybe arranged in a similar fashion, but imposed thereover.

I prefer that the complete form for any particular job be made up of aseries of units. Preferably, each unit should terminate in the base of achannel, as shown along the lower edge of Figure 1.

Although positive joints between the several units are not usuallynecessary, I find that it is preferable to join the units by adhesivesor in other mechanical ways, particularly where the joints are notprotected by falsework.

I have shown in Figures 8 through 11 two specific, forms of mechanicaljoints. According to Figures 8 and 9, I would provide a reinforcingbinding 2| which would fit over the free edge of the unit and firmlybind the same. These binders are preferably made of metal, althoughother equivalent materials may be used in lieu thereof. As shown inFigure 8, the binders 2| are provided with spaced tongues 22, and thesetongues may be bent over and around the binder of an adjoining sectionat the spaces between the tongues of such adjoining section. Thesespaces are preferably of the same width as the tongues. If necessary,suitable riveting may be employed to secure the binders to the form.

An alternative form of securing means is disclosed in Figures 10 and 11.Here also I employ a binder 2|, but beads 23 are formed on this binderin place of the tongues 22. A spring clip 24 may be employed to claspabout the beads and hold such beads and their respective units in firmengagement. The clip may be continuous or not, as desired; and may beclosed down on the beads by the use of a pair of pliers, if necessary.It will be observed that the securing means shown in Figures 8 through11 permit of the ready assembly of a series of units. Therefore, themolding forms may be made up of standard size, and merely assembled insufficient numbers for any particular job.

If desired, I may use additional structure in assembling my forms, suchas shown in Figures 12 and 13. In this instance the falsework mayembrace a plurality of suitable uprights 25, provided with a mounting 26at its top, to which guy ropes 21 may be attached. The mounting 25 maybe provided with V-shaped and intersecting channels 28 which are adaptedto receive V- shaped and intersecting channel members 29. The members 29are of substantially the same shape as the channels of the molding form,as shown in Figure 13. These channel members 29 are preferably made ofmetal, although of course otherv materials may be employed.

As stated, the channel members 29 correspond to the channels of themolding form, and are adapted to support such form. In assembling theform, the form is merely inserted in the channel member 29. For thistype of construction, I may use a special arrangement for the concretereinforcing members. As shown in Figure 12, the reinforcing rods l5 areprovided along one side with V-shaped truss members 31.

The reinforcing rods l5 may be arranged either before or after the formsare arranged in the channel members 29. In this type of structure thechannel members 29 are provided with holes 33, and corresponding holesmay be formed in the channels of the molding form. Pins 34 are adaptedto be inserted through these holes, and the trusses are so arrangedwithin the mold channels that the pins 34 securely hold the reinforcingrods l5 in position.

As will be hereinafter pointed out, the strengthening ribs 5 may extendinwardly of each form, in contradistinction to extending outwardly intothe channels as shown in Figure 4. In connection with the device shownin Figures 12 and 13, it is sometimes preferable to have suchstrengthening ribs extend inwardly and lie fiat against one or the otherwalls from which the rib is formed. As shown in Figure 13, the rib 5will therefore rest between one side of the channel member 29 and thecorresponding wall 2. Incidentally, when employing the channel member29, it is preferable to have the trusses of certain of the reinforcingrods 15 higher than the trusses of other rods, and the angle members.are designed to overlap in the same amount and to compensate for theoverlap of the rods, or the overlap may be taken up in the height of thetruss.

While I have referred above to a mold form provided with transversechannels, it is within the scope of my invention to provide such a formwhich has only parallel channels. Such a form is disclosed in Figures1'7 through'20. In this case, the flat surfaces I run the length, or thewidth,.of the entire unit, as do also the channels 3. When employingsuch a construction, I prefer to give additional support by reinforcingribs 35. These ribs preferably extend downwardly from the form, althoughthey may readily extend above. These ribs may be fastened together bymeans of staples or rivets 36, and may be properly reinforced ifnecessary.

Figure 20 shows the blank from which such a form is made. This blank issuitably scored or stamped to indicate the lines along which the foldsshould be created, and in Figure 20 the dotted line 31 indicates thefold at the base of one channel; the lines 38 indicate the folds at thetop of that channel; and the lines 39 represent the folds at the top ofthe two contiguous channels. Lines 4| and 42 indicate the places atwhich the transverse folds must be made in 'order to form thereinforcing flanges-36, the fold at line 42 being the lower part of suchflange. Diamond-shaped cut out sections 43 are necessary in order topermit of theproper folding, such cut out portion 43 providing for theline 44 shown in Figure 1'7.

It will be observed that in the form of mold shown in Figures 17 through20, no provision is made for the strengthening ribs 5, or any equivalentstructure. Therefore, in order to maintain the reinforcing rods l5 inposition I provide a stirrup-like member 45, which extends across thechannel and is turned at its ends to grip the walls of the channel. Ihave shown at 4511 a modified form of stirrup-member which providesadditional support for the form. In this modification, the stirrupextends down and around the outer side of the channel, and the free endsaretwisted. The stirrup member 45a may, if desired, be used in lieu ofthe device shown in Figures 8 through 11 as a means for securing twosections together.

It is of course obvious that the channel of Figures 17 through 18 may beincreased in width if desired, the same as in the case of the formshown-in Figures 14 through 15. This is accomplished by merely insertingan additional fold in the blank. As stated above, it is also to be notedthat the strengthening ribs 35 may be upturned, and when this is donethe stirrup 45 may be omitted, inasmuch as such upturned ribs will serveto hold'the reinforcing rod I5 above the base of the channel.

Reference has been made above to the fact that the strengthening ribs 5may be turned inwardly. Such a construction is shown in Figures 21 and22. The same pattern is employed in this case as in the case of Figure3, and the sole modification resides in extending the ribs inwardlyinstead of outwardly. When so extended inwardly, as best shown in Figure22, the rib 5 normally subtends the angle between the two adjoiningwalls. The ears [4 may be employed in this case, the same'as when theears extend outwardly, or other suitable securing means maybe employed.

The molding form may be made up of various materials. As heretoforestated, corrugated fiberboard may be used, or relatively heavycardboard, metal, or reinforced fabric. In all events, the materialshould have sufficient strength and stiffness so that when it is bentinto the desired form it will meet the stresses and strains imposed uponit during the initial setting of such superimposed material. It will beapparent that various substances will meet such requirements, and Iprefer that the most economical be employed. As stated, I prefer asufficiently inexpensive material so that it will not be necessary toattempt to salvage the molding form after the concrete has set. Incertain instances, the form may be removed upon completion of the job,but usually I prefer to merely let it remain, and to cover the same withlathing, plaster, or other such finishing material. For practicalreasons, it may be advisable to employ a material that is weatherproofand fireproof.

One efficacious material for use in my molding form (particularly whenthe form is to remain after the concrete sets) is made up by theincorporation of two or more substances, whether by interweaving,compressing, 0r cementing. One of these substances should possesssufficient stiffness and tensile strength for effectiveness instructural design, whether asa tensional member or merely as astiffener. The other substances should serve as a bulk or body, andshould have relatively high absorptive qualities, so that it will adhereto the material superimposed upon it, and sufficient strength to retainthe material during the required period; From the foregoing, it isobvious that a piece of wire lath, for example, shaped and coated with asufliciently fibrous material as gypsum or asbestos cement orasbestos-asphalt would serve the purpose of the form. Or burlap or paperinterwoven with wire reinforcement or such reinforcement cementedbetween or upon paper or felt would accomplish the same result; or aclothor woven membrane with wire threads interwoven at suitableintervals, and, if necessary or desirable, starched or varnished orotherwise filled.

It is also obvious that I have provided a novel design for molding formsand with respect to this design, materials other than those mentionedabove may be employed. For instance, the form may be made up from aceramic material, such as terra cotta, metal, metallic material, or anyother suitable substance.

It will be noted from the foregoing that I have provided an economicalmolding form that may be readily assembled, and which is suificientlyinexpensive so that it may be either left in the structure, or at leastno effort need be made to salvage it. It will be appreciated that mybasic invention is sufficiently flexible to meet varying conditionsencountered in structural work. It is of course apparent that it may beused not only for the constructionof flat surfaces such as floors androofs, but may also be employed for walls, arches, pillars and otherelements in buildings. Its light weight and small bulk facilitatetransportation of it, and it may therefore be made up in standard unitsand manufactured at factories on a large scale; The small contact pointsto applied materials, such as metal, lathe and plaster, make a water-,moistureand stainproof construction possible.

It will of course be apparent that various combinations may be madeamong the several individual elements referred to above and depicted inthe drawings. For instance, the structure shown in Figure 1 may beprovided with reinforcing ribs such as 35 shown in Figure 17, or withstirrup members 45 or 45a such as shown in the same figure. Again, thefalsework and channeled members disclosed in Figures 12 and 13 may beemployed with forms such as those shown in Figures 16 or 19. In otherwords, the details heretofore mentioned may be readily incorporated inany of the basic forms of my invention.

While I have shown and described the preferred embodiment of myinvention, I wish it to be understood that I do not confine myself tothe precise details of construction herein set forth, by way ofillustration, as it is apparent that many changes and variations may bemade therein, by those skilled in the art, without departing from thespirit of the invention, or exceeding the scope of the appended claims.

I claim:

1. A form for molding structural material com-. prising a strip of apliable plane substance bent to form a plurality of raised sectionsseparated from one another by intersecting channels.

2. A form for molding structural material comprising a pliable substanceforming a plurality of raised and flat surfaces,'sloping surfacesextending from such raised portions to intersecting-channels whichseparate the raised portions.

3. A form for molding structural material comprising a relatively lightand pliable substance bent to form a plurality of raised planularsurfaces, surfaces extending from such planular surfaces to channelsseparating the raised portions, and means integral therewith to maintainabove the base of each channel a reinforcing member for the structuralmaterial.

4. A form for molding structural material comprising a plurality ofraised planular surfaces, surfaces extending downwardly from suchplanular surfaces to intersecting channels separating the raisedportions, and means integral with the downwardly extending surfaces andlocated at the intersection of the channels to support a reinforcingmember for the structural material above the base of each channel.

5. A form for molding structural material comprising a plurality ofcontiguous frusto-pyramids, so arranged as to form intersecting channelstherebetween, each of the walls of the frustopyramids being extended toform strengthening ribs along the lines of junction of the walls.

6. A form for molding structural material comprising a plurality ofcontiguous frusto-pyramids so arranged as to form intersecting channelstherebetween, each of the walls of the frustopyramids along the line ofjunction with anading point of intersection of two channels to form astrengthening rib.

7. A form for molding structural material comprising a plurality ofcontiguous frusto-pyramids so arranged as to form intersecting channelstherebetween, each of the walls of the frusto-pyramids along the line ofjunction with an adjoining wall being extended into the correspondingpoint of intersection of two channels to form strengthening ribs, oneedge of said rib being adapted to abut against similar ribs from anadjacent frusto-pyramid.

8. A form for molding structural material comprising a plurality ofcontiguous frusto-pyramids so arranged as to form intersecting channelstherebetween, each of the walls of the frustopyramids being extended toform strengthening ribs along the lines of junction of the Walls, saidribs projecting inwardly of the frusto-pyramid.

9. In a form for molding structural material made up of a plurality ofraised portions separated by channels, supporting walls extending fromthe raised portions to the adjacent channels, each Wall being extendedbeyond the normal point of intersection with an adjoining wall, theextensions of two adjoining Walls being coextensive and lying flush withone another, corresponding cut away sections in each extension, andmeans adapted to extend through such cut away sections to maintain theextensions together.

10. A form for molding structural material comprising a plurality ofsections of a pliable substance bent to form a plurality of raisedsections separated from one another by channels, each section beingprovided along one edge with a reinforcement, and spaced ears on thereinforcement adapted to engage a reinforcement on an adjoining sectionto securely bind the two sections together.

11. A form for molding structural material comprising a plurality ofsections of a pliable substance bent to form a plurality of raisedsections separated from one another by channels, each section beingprovided along one edge with a beaded reinforcement, and a clip adapedto engage the beads when two sections are juxtaposed to securely bindthe two sections together.

12. A device for use in the pouring of structural material comprisingsuitable falsework, a chan neled member mounted on said falsework, amolding form supported by the channeled member, and reinforcements forthe structural material, said reinforcements being trussed in thechannel below the center of gravity in the structural section.

.angularly disposed at the reinforcements being supported within thechannels of the molding form by means of a truss and pins extendingthrough the channel member and engaging the truss.

14. A form for molding structural material comprising a plurality ofraised sections separated from one another by channels, said channelsbeing of sufficient width to accommodate a plurality of reinforcingmembers for the structural material, and means integral with thechannels for maintaining the reinforcing members above the base of thechannels.

15. A form for molding structural material comprising a strip of pliablesubstance bent to form a plurality of raised sections separated from oneanother by V-shaped channels, reinforcements formed by bending the stripat an angle to the channels, and stirrups extending across the channelsand adapted to maintain a reinforcement for the structural materialabove the base of the channels.

16. A form for molding structural material comprising a strip of apliable substance bent in one direction to form a plurality of raisedsections separated from one another by parallel V-shaped channels andbent in another direction to form transverse strengthening ribs, andspaced stirrups extending across the channels and around the exterior ofthe base thereof.

17. A form for molding structural material comprising a strip of apliable plane substance bent to form a substantial frusto-pyramid with areinforcing rib along the junction of each side wall. a

18. An article of commerce for use in construction comprising a strip ofa pliable plane substance bent to form a central plane with other planesangularly extending from the perimeter thereof and intersecting oneanother, the excess material of the plane substance forming stiffen-"-ing ribs at the intersections of the last-mentioned planes.

19. An article of commerce for use in construction comprising a strip ofa pliable plane substance bent to form a central plane with other planesangularly extending from the perimeter thereof and intersecting oneanother, the excess material of the plane substance forming stiffeningribs which bi-sect the angles of intersection of the last-mentionedplanes.

20. An article of commerce comprising a unit provided with a centralplane, planes angular thereto about the perimeter of the central plane,said angular planes intersecting, and other planes intersection of theangular planes.

21. A form unit for molding structural material comprising a pluralityof raised surfaces,

- and sloping surfaces extending from such raised surfaces and abuttingcorresponding sloping surfaces of adjacent raised surfaces, to therebyform intersecting channels which separate the raised surfaces.

DAVID M. BOWES.

